Industries · Manufacturing companies
Ship on the dateyou promised —not the one you hoped.
We build manufacturing systems that connect sales orders, production planning, bills of materials, stock, shop-floor progress, quality and dispatch — so the office and the floor work from the same plan.
- Sales orders & quotes
- Production planning
- BOMs & routings
- Materials & stock
- Shop-floor tracking
- Quality & NCRs
- Dispatch & delivery notes
- Costing
01Where factories lose days
The machines are ready. The information isn't.
Most late orders aren't caused by slow machines. They're caused by a missing sheet of steel, a drawing revision nobody saw and a plan that only lives on the production manager's whiteboard.
01Delivery dates are promised without looking at capacity
What happens
Sales confirms an order for two weeks' time; the production plan is a whiteboard and an Excel file that only the planner understands.
What it costs
Rush orders bump other jobs, overtime becomes routine and customers hear about delays after the date has passed.
With one system
Sales sees real capacity by machine and line before promising a date, and every confirmed order lands in the same live production plan.
02Materials run out halfway through a work order
What happens
Stock is counted in a spreadsheet, BOMs sit in engineering files and purchasing hears about shortages when the floor stops.
What it costs
Machines idle while a lorry is chased from Sharjah, emergency buying at higher prices and work orders split in half.
With one system
Every released work order reserves its BOM against live stock. Shortages show before release, with purchase requests raised for approval.
03Shop-floor progress is known only by walking the floor
What happens
Supervisors write progress on job cards; the office finds out a job is stuck at welding when the customer calls.
What it costs
Planners re-plan blind, bottlenecks move around unnoticed and nobody can answer “where is my order?” without a phone call.
With one system
Operators record start, finish, quantities and scrap at each operation from a tablet or scanner, so the plan updates as the floor moves.
04Drawing revisions reach the floor late
What happens
Engineering updates a drawing and emails it; the printed copy at the press brake is two revisions old.
What it costs
Parts made to the wrong revision, rework, scrap and arguments about who approved what.
With one system
Each work order links to the current approved drawing and BOM revision, and a change after release is flagged to the operation it affects.
05Quality records are paper forms in a folder
What happens
Inspection sheets, non-conformance reports and customer complaints are handwritten and filed by month.
What it costs
Repeat defects aren't spotted, certificates of conformity take hours to compile and audits mean days of searching.
With one system
Inspections, NCRs and corrective actions are recorded against the work order, batch and machine — searchable, linked and ready to export.
06Nobody knows the real cost of a job
What happens
Quotes use standard rates; actual labour hours, scrap and machine time are never compared afterwards.
What it costs
Some product lines quietly lose money and quotes for repeat work are based on guesses.
With one system
Actual material, labour, machine time and scrap are captured on each work order, so quoted and actual cost sit side by side.
02Factory platform preview
What your factory system could look like.
Switch between the views a planner, supervisor, storekeeper, quality inspector and plant manager would use. Every screen is designed per factory in discovery.
Illustrative interface with sample data — your system is designed around your products, machines and routings.
Illustrative demo · sample dataCan you picture your plant on one plan?
Build your factory system03Solutions
The parts of a factory system — chosen for your factory.
Dates promised against real capacity
Quotes & sales orders
Quotes built from your BOMs, routings and rates; confirmed orders flow into planning with the customer's drawings, delivery terms and promised date attached.
- Quotes from BOMs and routings
- Capacity check before promising
- Customer drawings and revisions
- Order status for sales and customers
Dates promised against real capacity
Quotes & sales orders
Quotes built from your BOMs, routings and rates; confirmed orders flow into planning with the customer's drawings, delivery terms and promised date attached.
- Quotes from BOMs and routings
- Capacity check before promising
- Customer drawings and revisions
- Order status for sales and customers
Not every factory needs every module. We scope the ones your operation actually uses, and add the rest when you need them.
04AI inside the system
AI that helps the planner keep up with the floor.
AI in your factory system works on its own records — orders, BOMs, plans, stock, operation logs and quality data. It finds conflicts, drafts re-plans and explains what happened; your planners, engineers and inspectors decide.
AI never releases a work order, changes a BOM or routing, approves a quality result, lifts a hold or places a purchase order on its own. It never touches machine controls or safety systems. Every suggestion shows the records it used, and production, engineering and quality keep the final say.
- 01
Re-planning assistant
Planner approves changesLaser cutter 1 is down for four hours. What do we move?Lists the operations affected, shows which can move to the second laser or another shift, and estimates the knock-on effect on promised dates. The planner reviews and approves the re-plan before anything changes on the floor.
- 02
Capacity-aware promising
When can we deliver 1,200 m of cable tray?Checks BOM material, supplier lead times and free capacity at each routing step, and suggests a realistic date with the step that limits it — so sales can promise with confidence.
- 03
Drawing and PO reading
Engineering confirms the BOMA customer sends a purchase order and five PDF drawings.Extracts quantities, part numbers, revisions, materials and delivery dates, matches them to existing products where they exist and drafts the sales order and a BOM starting point for engineering to check.
- 04
Quality pattern spotting
Inspector decidesAre we seeing repeat defects?Groups NCRs by defect, operation, machine, material batch and shift, and flags patterns — for example coating thickness issues clustering on one oven setting — for the quality team to investigate.
- 05
Plant questions in plain language
Why did on-time delivery drop last month?Answers from your own order, plan and operation records — which orders were late, at which step, and why — with the records behind each figure.
05A day with ORCHESTR
One production day, two ways.
- 05:45Shift starts from the live planThe day shift sees the plan by machine, with last night's quantities, scrap and downtime already recorded.
- 08:00Shortage known before releaseThe work order was held at release because the sheet was short; the operator is already running the next job.
- 10:30Revision flagged at the operationThe new revision is linked to the work order and the operator sees the change flag before starting.
- 13:00Status in secondsSales sees the work order at assembly with quantities complete, and gives the customer a real answer.
- 15:30NCR linked and searchableThe NCR is linked to the work order, oven and powder batch — and to the similar defect three weeks ago.
- 17:00Dispatch from what's packedPacking lists and delivery notes come from what's actually packed; the invoice follows proof of delivery.
- 19:30Plant manager's viewOutput, scrap, late orders and utilisation by work centre are on the manager's phone.
An illustrative day — every system is designed around how your team actually works.
06Integrations
Works with what your factory already uses.
Integrations depend on what each provider exposes — we confirm every connection in scoping before committing to it. Names are examples of categories we work with, not partnerships.
- ERP & accounting
- SAP Business One (via API)OdooMicrosoft Dynamics 365 Business CentralZoho BooksTally (via export)
- Engineering
- CAD and PLM BOM exportsDrawing files (PDF, DXF)Existing engineering databases
- Shop floor
- Barcode and QR scannersTablets and shop-floor terminalsLabel printers
- Machine data
- OPC UA or MQTT (where machines expose them)PLC and sensor gateways (where available)Machine logs via export
- Messaging
- EmailWhatsApp Business APIMicrosoft Teams
- Data
- Spreadsheets & exportsExisting databasesBI tools
07How we build your system
Built around your factory — not a template.
- 01
Understand your business
We learn how the business actually runs — people, tools, hand-offs and where time is lost — before proposing anything. - 02
Map your workflows
Every workflow is mapped end to end: who does what, when, with which information, and what should happen automatically. - 03
Design your system
Screens, records, permissions and integrations are designed around those workflows, and the scope is agreed in writing. - 04
Build and integrate
We build in stages and connect the tools you keep, so your team sees working software early and gives feedback as we go. - 05
Test and launch
We test with real scenarios, migrate the agreed data, set up roles and access, and onboard the team. - 06
Support and improve
After launch we support the system under an agreed arrangement and extend it as the business changes.
08Why it matters
What changes for the factory.
We don't quote savings we haven't measured. In discovery we baseline how your team works today, so improvements can be tracked against your own numbers.
Dates customers can rely on
Sales promises against real capacity and material, not hope.Fewer stops for missing material
Work orders reserve their BOM before release, so shortages appear in the office first.A floor the office can see
Progress, scrap and downtime are recorded where the work happens, as it happens.The right revision on every job
Drawings and BOMs are controlled and linked, so rework from old revisions becomes rare.Quality evidence on hand
Inspections, NCRs and certificates are linked to the job — ready when the customer or auditor asks.Pricing based on actuals
Quoted and actual cost per job sit side by side, so the next quote is better.
09Possible use cases
How different factories could use it.
Examples of what we could build — not completed client projects.
Every order a little different
A sheet metal and fabrication shop where each order has its own drawings, BOM and routing — quoting, planning and tracking built for one-off and small-batch work.
Steady lines, tighter margins
A plant running standard products in batches, focused on capacity planning, material reservations, scrap tracking and cost per unit.
Dubai and Abu Dhabi on one plan
Two plants sharing orders, stock and machines, with transfers between sites and a combined view for management.
The shop-floor layer the ERP lacks
Keep the ERP for finance and purchasing; add planning, shop-floor tracking and quality on top, synced via API.
FAQs
Manufacturing questions, answered.
Manufacturing & industrial
01We already have an ERP. Why would we need this?
Many ERPs handle finance, purchasing and inventory well but are weak on the shop floor: visual planning, operator data entry, revisions at the machine and quality records. We can build that layer and sync with your ERP via API, or replace the parts that aren't working — we'll tell you honestly which makes sense in discovery.
02Can it connect to our machines?
Sometimes. Machines that expose data over OPC UA, MQTT or through a gateway can feed run time and counts automatically. Older machines usually work better with operators recording start, stop and quantities on a tablet or scanner. We assess each machine in scoping before promising anything.
03Can operators use it on the floor?
Yes. Shop-floor screens are built for gloves, noise and speed: large buttons, barcode scanning, few fields and support for the languages your operators read. We test them with the people who'll use them before rollout.
04Does it handle multi-level BOMs and routings?
Yes. Sub-assemblies, alternates, operation routings with standard times and drawing revisions are all supported, and changes after release are flagged to the affected work orders.
05Will this help with quality audits?
It keeps inspection results, NCRs, concessions, corrective actions and certificates linked to the job, which makes the evidence easy to find. We don't certify your quality system or make claims about meeting any standard — that stays with you and your certifier.
06Can we migrate our items, BOMs and open orders?
Usually, from your ERP, spreadsheets or engineering exports. We map items, BOMs, routings, stock and open orders, clean duplicates and run the new plan alongside the old one before switching over.
07What does the AI do on the floor?
It doesn't run anything on the floor. It helps planners re-plan, helps sales promise realistic dates, reads incoming drawings and purchase orders, and spots quality patterns. Every change it suggests needs approval from the right person.
08Can it run across two plants?
Yes. Plants can have their own machines, stores and shifts, with stock transfers and shared orders between them and a combined view for management.
09How is a manufacturing system priced?
It's quoted after a discovery visit, based on the modules, the number of work centres and plants, and the integrations involved. Support and hosting are agreed separately and in writing.
Start here
Let's mapyour production.
Tell us how your factory runs today. We'll come back with how one system could connect sales, planning, the floor, quality and dispatch.
- 01We get back to you to arrange a call.
- 02A focused conversation about how your factory runs today.
- 03If there's a fit, a written scope and quote — no obligation.
Related guides